Seal and joint for deep-sea cables



June 23, 1942. w s -10 2,287,163

SEAL AND JOINT FOR DEEP-SEA CABLES Filed April 15, 1939 4 Sheets-Sheet 1 FIG.

2 SEALING (ml A0 VUL CAN/1181.5

man mm courouun FIG 3 m5 VULCANIZAILE m7 courounn VULCAN/ZAILE P an. C "Maw" 1 INVENTOR u. M. BISHOP ATTORNEY June 23, 1942. w. M; BISHOP 2,287,163

SEAL AND JOINT FOR DEEP-SEA CABLES Filed April 13, 1939 4 Sheets-Sheet 2 ,0 FIG 7 FIG. /0 212 2 1 5 as 63 pan 6/ 6 INVENTOR M. M. BISHOP ATTORNEY June 3, 9 wLM. BISHOP 87,163

SEAL AND JOINT FOR DEEP-SEA CABLES Filed April 13, 1959 4 Sheets-Sheet 3 lNVENTOR By W M'JB/SHOP AT TORNEV J1me 1942- w. M. BISHOP SEAL AND JOINT FOR DEEP-SEA CABLES Filed April 15, 1939 4 Sheets-Sheet 4 FIG. /5

FIG/7 n will INVENTOR m M. B/SHOP ATTORNEY results.

Patented June 23, 1942 sna AND JOINT roa near-sea CABLES Walter M. Bishop, Flushing, N. Y., assignor to Bell Telephone Laboratories, Incorporated, New York, N. Y., a corporation of New York Application April 13, 1939, Serial No. 267,632

16 Claims.

The invention relates to deep-sea cable systerns and more particularly to methods of and means for making seals and joints for deep-sea cables. I

An object of the invention is to produce insulating seals or joints for cables of this type. which will withstand high water pressures, which will form substantially perfect bonds with the cable insulation, and which will be practically as impervious to water as the insulation of the cable.

A more specific, object of the invention is to produce a joint between two deep-sea cable sections having the qualities enumerated above, but being especially adapted for joining two cable sections having characteristically different insulations, and particularly where one cable is insulated with rubber insulation and the other with an unvulcanizable compound, such as the several types of gutta-percha insulations or compounds.

Another more specific object of the invention is to produce an insulating end-seal for a deepsea cable adapted to terminate in and connect to a hollow housing containing apparatus and suitable for laying with the cable on the seav bottom, the seal in thiscase being formed between metal parts of the container andof the cable to form substantially perfect bonds therewith.

It is, however, a principal object of the invention to provide a method, and the necessary means therefor, of making seals or joints for elongated strands, such as deep-sea cables, which will require much less skill on the part of the workers than the methods hitherto in use, and which thus will be simpler and less costly than the prior methodaand which at the same time will give greater assurance of uniformly perfect It is therefore a more specific object to provide a method, and the necessary means therefor, of

pound until the compound has become substantially solid to prevent formation of shrinkage bubbles. The high pressure also serves to keep the sealing compound in intimate contact with the surfaces to be sealed.

In the case where a vulcanizable material is used for the sealing compound, the step of heating the mold and its contents may be made so that the compound will also become vulcanized and will be vulcanized to the sealing surfaces. In special cases it isdesirable to perform the molding operation in one mold and the vulcanizing operation in another mold or at least as a separate subsequent step. In all cases, however, the high fluid pressure is applied to the sealing compound during'the cooling process until the compound has fairly completely set.

In accordance with the invention, the liquid pressure is applied while the molds are tightly closed, so that only a very small amount of compound or cable insulation can leak out. The pressure is preferably applied through one or more pistons acting upon the plastic compounds or insulating materials enclosed by the mold. The pistons are forced into engagement with the plastics by any desirable means, and particularly during the cooling period the pistons are forced to follow up the shrinking plastics under high pressure, thereby securing continuous intimate contact between the various sealing surfaces and preventing formation of shrinkage bubbles or of blow-holes due to generation of gas.

In the case of a cable splice the cable ends are prepared by joining the conductors and fllling in the space between the cable insulations with a suitable thermoplastic sealing compound, building the joint up to the outside diameter of the cable insulation. A split mold is then clamped 40 tightly about the joint and heat is applied. One

molding insulating compounds in situ to permaplace within the mold. During the subs q ent cooling, pressure is applied to the enclosed comor more passages lead from the inside of the mold to a small pump-like device through which a plastic or fluid compound may be forced into the mold cavity during the heating and cooling processes. I

In the specific case of a cable, terminated in an apparatus housing adapted for laying on the sea bottom, it is preferable to provide a shopmade gland for insertion in the housing and for subsequent splicing to the cable end. The gland is made up of a bare central conducting rod or tube centered within a concentric metal insert by means of a hard insulating bushing, these parts having suitable shoulder portions in mutual engagement to withstand high sea pressure.

The space between these inner and outer conducting members is then filled with a thermoplastic sealing compound caused to adhere to the two opposite concentric surfaces. For this purpose the sealing compound is first molded about an intermediate portion of the central conductor to the size of the outer conductor in a split mold which is gradually closed during the heating period and into one end of which a piston is fitted having a central bore through which one free end of the central conductor passes. The other free end of the conductor passes through a hole formed in the other end of the mold. During the cooling, the piston is forced in against the plastic compound in the axial direction ,of the conductor, thereby continuously compressing the compound between all surfaces within the mold.

Thereafter the outer conducting element and the hard insulating bushing are placed in position on the molded unit and this assemblage is placed'in-another tightly closed split mold, having a similar arrangement of piston fitting into one end ofthe mold cavity and having bores for passing the free ends of the central conductor. By these means a high axially directed pressure may be applied'to the plastic sealing compound during the subsequent heating period thereby forcing the compound into intimate contact with the surface of the central conductor and with the inner surface of the outer conductor; and during the subsequent cooling process the piston can be adjusted to follow up the shrinking compound and maintain or increase the high pressure.

It sometimes is desirable to further strengthen the seal against water leakage and pressure by vulcanizing the sealing compound to the surfaces to be sealed. This is particularly of advantage in the case of the shop-made gland referred to above.

and be kept free from contamination until the molding operation takes place. However, in accordance with a specific feature of the invention the brass surface is treated immediately before the molding and vulcanizingoperations by rubbing or rolling contact under high pressure with polished, rounded surfaces of hardened steel bodies, such as rollers, balls, or dies. It appears that the pressure of the steel bodies moving relative to the brass surface must be sufficiently high to cause'a metallic how in the brass surface, that is, to cause burnishing of the brass surface,-

whereby a high degree of smoothness is attained. Whatever may be the action of this treatment, exceptionally perfect vulcanized bonds between such burnished brass surfaces and rubber have readily been secured in this manner.

It is an important feature of the invention that a the heated mold or portion thereof containing a compound in a more or less fluid or plasticized condition should be cooled from a point remote from the point on the mold at which the follow- For this purpose the two concentric conducting members are made of brass and the sealing compound is suitably prepared for .vulcanboth metal and compound to smooth and clean sealed to the attached cable sections in according proceeds in one direction, fluid compound may be supplied in a direction toward the shrinkingcompound at allstages of the cooling periodto prevent formation of any voids, and to insure that the shrinking compound is kept in close contact with its contiguous surfaces until it has reached a solid state at which no further shrinkage will occur. Thus supplemental compound may be supplied or shifted lengthwise of the mold to keep the cooler part of the mold filled and thus insure that the radial dimensions of the seal will not be reduced.

The various features of the invention will now be described as applied to specific preferred embodiments of characteristically different types and reference will be made to the accompanying drawings, in which:

Fig. 1 is a general view of a housing inserted between two cable sections, parts being broken away to show details of the protecting structure;.

Fig. 2 is a sectional view of an end-seal for joining a cable end to the housing, it includes a gland sealed into the housing with a plastic compound constructed in accordance with the invention and it'includes a joint between the gland and the cable terminal which may also be constructed in accordance with the invention;

Fig. 3 is a detail view of a joining seal, prepared in accordance with the invention, between two spliced cable sections, one of which is insulated with a vulcanizable compound and the other with a non-vulcanizable compound;

Fig. 4 shows the laying of a housing inserted between two cable sections and sealed thereto' in accordance with the invention;

Figs. 5, 6, 9 and 10 are view s of molds employed in the preparation of the seal for the housing shown in Fig. 2;

brass conductor for vulcanization thereto of a vulcanizable compound; and

Figs. 15, 1.6 and 1'7 are views of a molding structure employed in the preparation of the joining seal between two spliced cable sections. Fig. 15 is a detail view showing the mold proper with one-half removed, and with-a cable splice in position for curing. Figs. 16 and 1'7 are front and end elevations of the entire structure.

Fig. 1 shows a housing, with parts broken away,

ance with this invention. The housing comprises a helix ll of steel or other material which is capable of withstanding deep-sea pressures. A pliable copper jacket 28 covers the helix [I The jacket 28 may be constructe'd'of other material which is pliable and which will remain impervious to water. A layer of jute I is wound around the copper jacket 28. Over the jute, the armor wire 2 of the submarine cables is placed. Another layer of jute 3 is wound around the armor win 2. Fig. 2 shows details of an end-seal for the housing shown in Fig. l. The end-seal or gland, shown in Fig. 2, is fitted intothe elongated steel helix H which is capable of withstanding deepsea pressures.

A steel end-plate [2 supports each end of the helix radially and resists the end up pressure is applied, in order that, as the cool- 16 thrust due to the undersea pressure. The helix supports the steel end-plate l2 longitudinally by means of an internally threaded collar l3 which spectively, in their outer surfaces.

is fixedly held to the plate [2 by means of the threads thereof. A copper ground-plate I, held in contact with an outer brass conductor or connecting piece I! by means of the internally threaded collar I2, has a terminal l8 fixedly attached thereto which passes through the endplate l2. The ground plate I4 is preferably soldered to the outer conductor II. A central conductor it having a shoulder passes through the outer conductor ll, the-ground plate I4 and the end-plate l2. The central conductor Ill may be either solid or hollow. The central conductor III is insulated from the outer conductor I8, the ground plate l4 and the end-plate l2 by means of a hard rubber insulator I! having a shoulder.

prevent appreciable extrusion of the insulator I! through the outer conductor l5 andof the conductor ll through the insulator l8, respectively, when these are subjected to sea bottom pressures. The axial length of the shoulders of both the insulator I1 and the conductor I must be suf-' flciently great for the shoulders to withstand deep-sea pressures without shearing. This construction and arrangement of the conductor Ill and the insulator ll results in preventing leakage of water between the outer conductor I and the insulator IT. A nut l8, held rigidly by means of threads on the end of the conductor l8, holds the conductor l8 and insulator I! to the outer conductor IS, with the aid of an insulator collar II which rests against the outer conductor IS. The central conductor i0 is separated from the outer conductor It by means of a vulcanizable compound 2| vulcanized to both conductors. The manner of vulcanizing the compound and its composition are described hereinafter in the consideration of 'Figs. 5 to 10.

Before vulcanization of the compound 2|,

Paragutta or other suitable insulating material 22 is joined to the vulcanizing compound 2| at a point beyond the end of the outer conductor I5. Before laying the cable and housing, the central conductor III is joined to a central conductor 23 of a submarine cable. "Paragutta insulation 24 of the submarine cable is joined to the "Paragutta" insulation 22, surrounding the central conductor III, by Paragutta insulation 5. After the joining" operation, a sleeve or end-piece 20, having a long tube which surrounds the insulation of the central conductor l0 and a portion central conductor l8 and the sleeve 28, in addition to filling the space between the sleeve 28 and the insulations 24 and 5 covering the conductor 28 of the submarine cable which are surrounded by the sleeve 28. The outer conductor l5 and the sleeve 28 each have a groove 26 and 21, re-

The acket 28, comprising copper or other material which is pliable and impervious to water, completely covers the steel helix II. In addition, the jacket 28 covers the collar H, which is brazed to the a 3 jacket 28, and extends over the outer; conductor I beyond the point where the groove 28 of the outer conductor is located. Before the outer conductor is inserted in the jacket 28, the inside of the jacket 28 is tinned on the portion which covers'the outer conductor. Alter the end-plate l2, the ground plate I4 and outer conductor i5 have been inserted into the jacket 28, the end of the jacket is temporarily covered with a rubber sleeveto prevent entrance of water into the housing and the assembly is subjected to hydrostatic pressure. As a result of this procedure the jacket 28 is crimped into the groove 28 of the outer conductor.

The jacket 28 is soldered to the outer conductor [5 at the point of the crimp 28 in the soldering tool shown in Figs-11 and 12. The tool consists of two blocks 29 which, when closed with the aid of guides 30 and tightening screws 3|, have the contour which has been given to the jacket 28 at the point of the groove 28 of the outer conductor 15. The housing with jacket 28 is inserted in the tool and the screws 3| tightened to exert the desired pressure. Heat 'is applied to the plates 28 by means of two heated metallic cylindrical blocks 82. Preferably, the plates 29 are heated before insertion of the jacket 28 in order that the operation may be performed quickly, thereby preventing any deleterious effect on the rubber insulation.

After the jacket 28 has been soldered to the outer conductor or connecting piece IS, the outer conductor 15 is crimped into the groove2l in sleeve v2ll by temporarily covering the assemblage with a rubber tube and subjecting it to hydrostatic pressure. The outer conductor l5 and the sleeve are then soldered in a tool similar to that shown .in Figs. 11 and 12 and in a manner identical with the soldering of the jacket to the outer conductor. The crimping of the jacket to the outer conductor and the crimping of the outer conductor to the sleeve insures the forma tion of a metallic seal between the respective parts by means 'of the solder completely around the sleeve, outer conductor and jacket. As a further aid in preventing damage to "the rubber part of the housing, a soft solder having alow melting point is preferably employed in the soldering operation. To prevent corrosion at the point of jointure of the jacket and sleeve with the outer conductor, the sleeve is made of the same metal as the jacket and the end portion of the jacket, the exposed portion of the outer conductor and the adjacent portion of the sleeve are electroplated with the same metal as thatof the jacket and sleeve. The electroplating is represented in the drawing by the numeral 33. In addition to preventing corrosion, the electroplating 33 insures against leakage of water through the soldered joints. After electroplating, a plurality of rings are employed to produce a taper between the housing and the submarine cable. These rings are of gradually reduceddiameter from that of the end of the housing to that of the submarine cable, and are supported by the sleeve 20. One lead of the electrical apparatus. represented asa labeled block diagram in the drawing and contained within the housing, is

connected to the terminal I6 and the other lead are also satisfactory.-

ance with this invention and. connected into the cable, passesover two sheaves I and 1| and a drum 15 located on acable ship I5. The flexible nature of the housing permits the laying of the cable without the necessity of splicing of the cable on the cable ship for the connection of the housing.

Figs. and 6 show the mold for forming about the central conductor III the composite seal, comprising the compounds 2| and 22, one section of which is subsequently vulcanized to the conductor and outer conductor 5. The mold. consists of'two halves or dies 50 and 5| which are aligned with each other by means of two guide pins 52. A steel plate 53 is fixedly attached to the lower half of the mold 50 to prevent loss of the insulating compound. Another steel plate 54 having an aperture therein, through which the conductor l0 passes, is fixedly attached to the lower half of the mold 50. A steel plunger 55 is inserted to engage the shoulder of the conductor l0. Pressure may be applied to the plunger 55 by means of a spring 51. The pres shoulder portion of the conductor resting against the plunger 55.

A composition of the vulcanizing compound 2| which has been found satisfactory to produce one section of the seal is as follows:

' Parts Deresinated balata 40 Deprotenized rubber 50 Superla wax l Age rite resin (aldol-alpha-naphthylamine) 1 Zinc oxide 50 Captax (mercapto-benzo-theozole) .5 Stearic acid .5

Sulphur 3 Petrolatum 5 The material known commercially as Superla wax, employed as an ingredient in the vulcanizing compound 2| and in the Paragutta 22, is I a solid paraffin hydrocarbon wax derived from petroleum and having a melting point between 71 and 77 C. A range of materials having somemold 5| is placed against the compounds and the mold is inserted in a press, which previously has been heated to approximately 100 C., to exert a slight positive pressure. A slight pressure is maintained by frequent readjustment of the press during a ten-minute heating period for the mold, compound and Paragutta. At the end of ten minutes the mold is gradu: llyclosed and should be closed till the end of an additional five-minute period. During this latter period at the first appearance of the compound on the side of the mold opposite the plate 53, the molding is temporarily terminated while the plate 53 is removed. This procedure permits the com Y pound to fiow in either direction as the mold is finally closed, thus reducing disturbance of the compound around the central conductor l0.

As soon as the mold 50, 5| is closed, steam employedv to heat the press is turned off and cold water passed through the ress to cool the mold.

During the process of cooling. the pressure in the mold is gradually increased by compressing that of the end of the premolded specimen shownin Fig. 8. The mold is adapted to fit on to the outer conductor IS. The outer conductor I5 and steel mold '50 are secured to each other by a clamp comprising two steel plates 62' and 63 held by two rods 54.1 The two rods 64 also support another plate 5|. A plunger is inserted in the interior of the mold 50 and causes pressure to be exerted on the compound seal during vulcanization. Pressure is roduced on the plunger 55 by fneans of a spring 65 and a threaded sleeve 61. The sleeve 51 is threaded in the plate 5| and is concentric with the plunger 55. By turning the sleeve-51 pressure is applied to the plunger. A steel mold 58 is adapted to hold the end of the rubber insulator ll of the housing which protrudes beyond the outer conductor I5.

what higher and somewhat lower melting points I Reference' is made to United States patent to Wendt. and Banta 1,735,555, granted on'November 12, 1929, for a further description of such waxes and their modes of preparation.

The compound 2| is placed in the mold between the COI'ldUCtOlXI and the plate 50 for a distance from the shoulder of conductor III which is slightly greater than the length of the outer conductor I5. At the other-end of the mold, Paragutta 22 is inserted which comprises:

- 1 Parts :Deresinated balata 40 -Deproteinized rubber 50 Superla wax 10 Preferably, the compound 2| and Paragutta" 22, before being placed in the mold, are cleaned with a cloth saturated with benzol to remove any'discoloration which may have accumulated upon the.compounds. The upperhalf of the The hard rubber insulator I1 is inserted in the outer conductor and the premolded specimen shown'in. Fig. 8 is inserted in the mold 50. The mold .60, the outer conductor |5 having the hard rubber bushing l1 inserted therein, and the mold 68 are clamped together by means of the plates 52 and 53. Pressure is applied to the plunger by the rotation of the sleeve 51 until a pressure of between 1500 and 3000 pounds per square inch is exerted on the seal sections 2| and22. The device shown in Figs- 9 and 10 is then placed in an autoclave and the compound, 2| curedfor a period of thirty minutes at a temperature of approximately 142 C. (steam ressure of approximately 40 pounds per square inch). After curing, the device and seal are permitted to cool, pressure by means of the plunger being exerted during the cooling operation. After cooling, the seal, outer conductor I5 and insulator l'l are removed from, the mold. Compound 2| has now diameter of the bore through the outer con-,

ductor is made slightly undersize and is brought on the central conductor by rotating it whilepassing it through a plurality of steelballs or rollers under pressure.

As an example of this treatment of the brass surface of a conductor for the purpose of vulcanization thereto of a rubber-sulphur compound, a typical arrangement is shown in Figs. 13 and 14. The die 8| includes a general mounting structure 82 with three grooves 83 each adapted to guide a slide 84 in a radial direction with respect to the center of the die. Each slide 84 may be forced toward the center by means of the threaded end of a rod 85 which can be turned by a screw-driver. Each slide 84 has a cupshaped end engaging a ball 86, also placed in the groove 80. As a practical modification, each of the slides 84 may be of hardened steel and have its inner end shaped and polished to conform with the surface of the conductor as shown in Fig. 14a; in this case the ball 86 will be omitted.

The die is placed about the brass conductor 80 and the rods 85 are tightened up to place the balls 86 in close contact with the conductor. This assemblage may then be placed in a lathe to effect a relative rotary movement between the conductor 80 and the balls 86, and simultaneous therewith a relative longitudinal movement between these parts. Thus, the conductor may be held stationary in the lathe while the die mounted in a chuck is rotated about the conductor,

the chuck at the same time being moved longitudinally of the conductor by a finely threaded spindle. By this arrangement of moving parts, all points of the surface of the conductor will be placed in frictional contact with the balls of the die.

The pressure on the balls against the conductor should be high enough to burnish the surface of the conductor, 1. e., to cause a cold flow of the brass in the surface of the conductor, thereby producing an extremely smooth virgin surface. The balls should be of hardened, highly polished steel. Care should be taken that the surface of the conductor is clean and is not contaminated during the process or before it is protected by the application of the vulcanizable compound which, of course, also should be cleaned at the time. of its application to the burnished brass surface to prevent contamination thereof.

It has been found that a high degree of ad-' Referring now to Fig. 3 which shows detailsof a seal between two cable sections, the cable end lI has a central conductor I02 insulated with a vulcanizable compound I03, and the cable end III has 'a central conductor H2 insulated with a non-vulcanizable compound H3. The compound I03 may contain rubber as one of its principal ingredients and includes vulcanizing agents and accelerators; it may be similar to the compound 2|, described above. The compound II3 may contain gutta-percha as one of its principal ingredients or it may be similar to the Paragutta compound 22, described above.

The ends of the cable cores are prepared for the splice by removing the insulation from a short end of the central conductor and shaving the insulation to the shape of a cone, as shown at I04, taking care to avoid contamination of any sort of the shaved surfaces. The conductors I02 and H2 are then joined, as by soldering. The space between the cone surfaces I04 is then filled to the diameter of the core insulation by wrapping of successive layers of thin strips of insulation which have been softened in hot water. The strips are stretched nearly to the breaking point during the wrapping process and are applied to form uniform layers I05 each of substantially constant diameter throughout its length. For a splice of this type, it is preferable to use alternate layers of vulcanizable tape I00 of a composition similar to insulation I00 and non-vulcanizable tape I01 similar to insulation IIO; however, the layers of vulcanizable tape I06 are stopped short some distance from the Paragutta" insulation I I3 and the layersof tape- I01 are stopped short some distance from the vulcanizable insulation I00 in such a manner that three zones are formed within the filling between the cone surfaces I04, namely, the zone A containing only vulcanizable compound, the zone C containing only non-vulcanizable compound and the zone B containing alternate layers of both sealing compounds. If desired, the seal gay be built up entirely of layers of vulcanizable When the splice has been completed the joint is placed in a suitable mold, such as shown in Figs. 15, 16 and 17, for the purpose of forming the insulating layers into a homogeneous filling between the cones I04 and to seal this homo- "geneous compound to the conductor and the cone surfaces I04 by vulcanization, so that a seal'will be obtained which is substantially as water-tight as the-cable insulating compounds.

The molding structure, shown in Figs. 15, 16 and 17, comprises a split steel mold I20 and a pressure structure I2I for supplying supplemental compound under a follow-up pressure to the seal within the'mold. The mold I20 is made up of two substantially identical halves I22 and I20, each having a groove I24 for receiving the splice and short portions of the cable ends IM and III. After the two halves of the mold have been placed about the splice they are closed tight about the splice by means of bolts I25, guide pins and holes I26 serve to properly align the two halves. I

Each half of the mold I20 has channels in the main body thereof for passing cooling and heating media. Thus, the channels I3I and I02 in each half may be connected to a system for supplying cold circulating water to the mold to keep the cable ends cool during the molding and curing operations. Channels such as I00 in the has been closed, with the exception that two cyl-,

leading through a reduced opening I31 to thesealing compound of the splice.

A supply of supplemental sealing compound I45 is then inserted in each of the cylinders it and I42 and is followed by plungers I46 and i411 fitting with a sliding fit into the cylinders @41- and I42, respectively. The supplemental compound may be inserted in the form of a solid cartridge or in any other desirable manner, the compound may be the same as the insulation on either cable end or may conform more closely to the sealing compound used in the splice. This compound must, however, be non-vulcanizable in order to remain fairly plastic until the splice has been cooled.

The pressure, structure I2I further comprises a frame of two yokes I5I and I52 with connecting bolts I53 and I54. The yoke I5I serves as a guide for a pressure rod I55 acting on the plunger I46; a spring I 56, surrounding the rod I55 and located between the yoke I5I and a shoulder I51 on rod I55, serves to apply pressure to the plunger I45. A pressure rod I BI is threaded through the yoke I52 and is at its free end I62 adapted to be screwed into contact by its other end with the plunger I41 for the purpose of applying a follow-up pressure directly to the plunger I41 and through the pressure frame and spring I56 to the plunger I40.

In the caseof a splice between cable ends requiring a non-vulcanizable sealing compound,

the splice may be placed centrally in the mold,

as shown in Fig. 15. However, in the case of a splice containing a vulcanizable compound, the

supplemental compound will be supplied through the passages I31 to the sealing compound of the splice. The pressure is increased to such a value that all voids within the mold will be filled, the air from such voids being forced out through the ends of the mold I20. M

For the purpose of vulcanizing a vulcanizable sealing. compound, the heating stage will usually be maintained for about thirty minutes with a temperature of approximately 142 C.

After the seal has been formed or cured, the steam is shut off from the tubes I33 and the mold is permitted to cool progressively from the end portions toward the center portion, where the supplemental compound is supplied. During this cooling stage the rod IBI must be continually tightened up to supply supplemental compound to the gradually shrinking sealing compound of splice should preferably be shifted relative to the passages I31 so that these passages will not be locked by the cured compound. Thus, in the case of the splice shown in Fig. 3, the splice should be shifted to the left in the mold shown in Fig. 15 sufflcient to bring the non-vulcanizable thus will retain their shape and dimensions. Thesealing strips I05 and the conical ends I04 of the cable insulatlons being subjected to the heat of the circulating steam will become plastic and more or less fluid. The sealingstrips I05 will I consequently flow into a physically homogeneous mass which will adhere closely to the conducting strand and will partially mix with the cable insulations along the cone surfaces I04.

During the heating. period the rod IBI is screwed into the end-piece I52, thereby exerting a pressure on both cartridges of supplemental,

compound I in the directions toward the cable splice. The cartridges I 45 also being subjected to the heat will turn into a plastic or semifluid state possible; that the splice be molded in a closed and, as .the pressure from rod, I5I is incre s the splice. The'pressure must be high enough to prevent formation of blow-holes due to gen-- After the cooling has progressed to the point where the entire sealing compound and the supplemental compound have returned to a sub-' stantially solid state, the pressure may be relieved by unscrewing the rod IGI; the molding structure is dismantled and the cable splice removed from the mold. The excess supplemental compound attached to the middle of the'splice is removed and any irregularities in the-surface of the splice are removed. The splice is then ready for application of the armoring.

It has been found that by this method of sealing the splice, the sealing compound is vulcanized closely to the conical surfaces of the cable cores and is so thoroughly united with the cable insulations along these surfaces as to practicallyform' a physically continuous layer of insulation about the central conductor, so that sea water is eflectively prevented from entering the seal.

The process of making a cable splice, as Just described, may be modified in several minor details without a departure from the scope of the invention. Thus, the end of the mold I20 enclosing the cable end which is insulated with vulcanizable compound may, if desired, be heated by application of steam to the passages I3I during at least a part of the heating and cooling periods, with the object of promoting the'vulcanizing action at the surface of the insulation on the cable. end. vantageous, in building up the sealing compound between the conical surfaces I04, to use tape of vulcanizable compound for all the layers. The

same general process and the same molding structure may also be used in the splicingof the cable ends having similar insulating compounds, as in the case of two cable sections both insulated with paragutta or both insulated with a vulcanizable rubber compound.

In all cases, however, it is advantageous that v the space between the conical surfaces be built up originally with as small and few voids as mold sufficiently tight-fitting to permit the sete ting up of a very high follow-up pressure on the It may also be found adsealing compound; that a pressure be maintained particularly during the cooling period sufficiently high to prevent formation of shrinkage'bubbles due to generation of steam, and to fill all voids originally presentor arising due to shrinkage; and that the cooling of the splice should proceed, practically speaking, from points remote from the part of the seal at which the supplemental compound is applied and progress gradually toward that portion in order that supplemental material may be supplied longitudinally of the seal toward the cooled portions thereof.

Whereas preferred and alternative embodiments of the invention have been illustrated and described, various other, modifications may be made therein without a departure from the scope of the invention as defined by the appended claims,

This application isin part a continuation of my application Serial No. 71,411, :filed on March 28, 1936, which has issued as Patent No. 2,158,492 on May 16, 1939.

What is claimed is:

' 1. In a method of molding a seal about an intermediate portion only of an elongated strand, the steps of placing in a mold the'said portion of the strand and a predetermined quantity of a cold sealing compound surrounding said portion, of tightly confining said compound between contiguous surfaces of said mold, of heating the mold and contents to plasticize said compound, of applying a high pressure to said compound as confined within the closed mold to compress it and force it into close contact with the said strand, of cooling the mold and contents, and of preventing substantial relaxation of said pressure until the compound has cooled substantially to the solid state.

2. In a method of molding a seal about an intermediate portion only of an elongated strand, the steps of placing in a mold the said portion of the strand and a predetermined quantity of a cold sealing compound surrounding said portion,

of heating the mold and contents to plasticize said compound, of tightly closing the mold during said heating step to discharge excess compound therefrom, of cooling the mold and contents, and of applying an increasing pressure to said compound within the closed mold during the entire cooling of said compound to the solid state.

cover said surface and of molding, vulcanizing and cooling substantially to the solid state the compound within a tightly closed mold under a continued high pressure between the compound and the surface.

6. In a method of securing a bond of greatmechanical strength between a brass surface and a vulcanizable compound, the step of smoothing said brass surface by passing a smooth polished body of steel over said brass surface with a contact pressure sufilcient to produce a flow in said brass surface, the subsequent step of placing said vulcanizable compound in intimate contact with the uncontaminated smoothened brass surface, the subsequent step of vulcanizing said compound to said smoothened brass surface under high pressure during the heating and cooling periods thereof.

'7. A method of producing an insulating seal of great mechanical strength between two opposed brass surfaces which comprises smoothing each of said brass surfaces by passing a smooth polished body of steel over the surface with a contact pressure sufiflcient to rub out irregularities therein, placing a vulcanizable compound in intimate contact with one of said smoothened surfaces, placing the other smoothened surface in juxtaposition to the first of said surfaces, compressing said compound between said juxtaposed surfaces by pressure applied in directions parallel to said surfaces to force said compound into intimate contact with both of said surfaces, and vulcanizing said compound on to both of said surfaces.

8. Amethod of producing an-insulating gland of great mechanical strength between the two opposed concentric surfaces of an inner elongated brass conductor and of an outer cylindrical brass 3. In a method of molding a seal about an intermediate portion only of an elongated strand, the steps of placing in a mold the said portion of the strand and a predetermined quantity of a 7 cold sealing compound surrounding said portion,

of heating the mold and contents to plasticize said compound, of tightly closing the mold during said heating step to discharge excess compound therefrom, of thereafter applying a high pressure to said compound within the closed mold, of cooling the mold and contents to solidify said compound,

andof maintaining the said pressure on said compound substantially independently of shrlnking of said compound during said cooling.

4. A method of hot molding a seal about an intermediate portion of an elongated conducting strand which comprises placing the portion of the elongated strand and a predetermined quantity of a solid sealing compound surrounding said portion in a split mold, guiding the strand on both sides of said portion to center the strand in the seal, lightly closing the mold, plasticizing the compound by heating the mold, the compound and the portion of the strand, applying pressure posed to a portion of said inner conductor which comprises the step of passing the outer surface of said innencon'ductor in frictional contact with a rounded steel body under pressure sufficient to smoothen said outer surface, placing in a split mold said elongated inner conductor with a quantity of vulcanizable compound about an intermediate portion thereof, heating mold and contents below vulcanizing temperature, applying pressure to the mold to compress the compound and press it into intimate contact with said smoothened surface, cooling mold and contents, applying pressure to the compound in the axial direction of the conductor and maintaining the axial pressure during cooling to exclude gas from the mold and to prevent formation of gas therein, removing conductor and molded compound as a unit from mold, forcing a rounded steel body into frictional .contact with the inner surface of said outer conductor under pressure sufficient to smoothen said inner surface, inserting said removed unit into said outer conductor with a portion of said moldedcompound juxtae surface and in approximate engagement therewith to form an assemblage, placing the assemblage in the closefltting enclosure of a second mold, heating the second mold and contents at least to the vulcanizing temperature of said compound, applying axially directed pressure to said compound during the heating in said second mold to press said mold to prevent formation of voids within the mold.

13. A method of producing an insulating seal for joining two separated portions of cable insulation in a submarine cable, which comprises shaping the ends of the cable insulation to present a substantially conical surface towardthe joint, tightly wrapping a tape of insulating com- 9. A method of manufacturing a composite seal for an elongated conductor which comprises molding in a closed mold, substantially without vulcanization, a vulcanizable compound forming a section of the seal and a non-vulcanizable compound forming a contiguous section of the seal about an intermediate portion of the conductor under application of pressure to secure intimate contact between said sections of compounds and between said sections and said portion, and subsequently curing the vulcanizable compound whereby it is sealed to the conductor and to the non-vulcanizable compound, said pressure being supplied substantially in the direction of the length of the conductor.

10. A method of sealing a section of a vulcanizable insulating compound and an adjacent section of a non-vulcanizable insulating'compound to a middle portion of an elongated conducting strand and to each other which comprises molding, substantially without vulcanizing, the vulcanizable compound in contact with a part of said middle portion and the non-vulcanizable compound in contact with an adjacent part of said middle portion and in contact with the vulcanizable compound under application of heat and pressure in a mold, cooling the compounds in the mold and simultaneously therewith applying a pressure to the compounds in a direction parallel to the stran to prevent formation of blow-holes at the engagng surfaces between the compounds and betweenthe strand and the compounds, and subsequently curing the vulcanizable compound to secure continuous adherence of said cured compound in successive layers about the conductor core of said cable to entirely fill the space between said conicalsurfaces, clamping tightly a split-mold about the seal and the adjacent insulation portions, heating the portion of the mold containingthe said seal for plasticizing the said compound, cooling during the said heating step one end of the mold to maintain the cable insulation within that end in a solid state, discontinuing said heating and cooling the entire mold and contents until the seal has set, and forcingduring the said heating step and the subsequent cooling step additional insulating compound in plasticized form into the heated portion of said mold to maintain the seal under high pressure until it has set.

14. A method of producing an insulating seal of great mechanical strength between two opposed concentric, cylindrical, brass surfaces, which comprises smoothing each of said brass surfaces by passing a smooth polished body of steel over the surface with a contact pressure sufflcient to rub out irregularities therein, molding a vulcanizable compound in intimate contact with the inner one of said smoothened surfaces, placing the outer smoothened surface in juxtaposition to the inner of said surfaces, compressing said compound between said juxtaposed surfaces by pressure applied in a direction parallel to the pound with the non-vulcanizable compound and with the conducting strand.

11. A method of producing an insulating seal for the Joint between two compound-insulated conductors, which comprises thesteps of tightly wrapping a tape of insulating sealing compound about the joined conductors to fill the space bethe seal within the mold to prevent formation of voids within the mold.

12. A method of producing a sealing joint between two separated bodies of insulation about a I conducting strand which comprises the steps of filling the space about the strand between the prepared ends of said bodies with a quantity of insulating sealing compound, of placing the seal in a substantially tight-fitting mold, of heating and cooling the mold to plasticize and mold the sealing compound, and ofsupplying under high pressure 'during said heating and cooling steps additional sealing compound in plasticized form to an intermediate portion of the seal within the common axis of said surfaces to force said compound into intimate contact with both of said surfaces and vulcanizing said compound on to both of said surfaces during said compressio step.

15. A method of producing an insulating seal of great mechanical strength between two opposed concentric, cylindrical, br'ass surfaces, which comprises smoothing each of said brass surfaces by passing a smooth polished body of steel over the surface with a contact pressure sufficient to rub out irregularities therein, placing a cold vulcanizable compound about the inner one of said smoothened surfaces and molding the compound under pressure into intimate contact with said inner surface toform a substantially uniform layer of said compound about said inner surface, placing the outer smoothened surface about said molded compound in a mold, heating the mold and its contents and compressing within the mold said compound between the opposed surfaces by pressure applied in a direction parallel to the common axis of said surfaces to force said' compound into intimate contact with both of said surfaces and to vulcanize said compound I of said smoothened surfaces in a mold and molding the compound under pressure into intimate contact with said inner surface and at temperatures below the vulcanizing temperature of said compound to form a substantially uniform layer of said compound about said inner surface, placing the outer smoothened surface about said molded compound in a mold, heating the last said mold and its contents and compressing within the mold said compound between the opposed sur- 5 .both of said surfaces.

faces by pressure applied in a direction parallel to the common axis of said surfaces to force said compound into intimate contact with both of said surfaces and to vulcanizesaid compound on to WALTER M. BISHOP. 

